Method for making a flangeless seam for use in disposable articles

ABSTRACT

A method of making a flangeless seam for a disposable article including the following steps: A first member of the disposable article is provided. A conductive member is provided on the first member. The first member is folded about the conductive member providing opposing first proximal and first distal portions of the first member, the conductive member being disposed at least partially between the opposing first proximal and first distal portions. A second member of the disposable article is provided in a folded configuration juxtaposed at least a portion of the first member to form a laminate including the first member and the second member. An electromagnetic field is applied across at least a portion of the laminate to heat the conductive member to a temperature which joins at least a portion of the first member and at least a portion of the second member. The resulting seam can be opened to provide the article with a flangeless seam.

This application is a continuation in part of Ser. No. 08/855,651 filedMay 15, 1997.

FIELD OF THE INVENTION

The present invention relates to a method for making flangeless seamsespecially preferred for use in disposable, pant-like articles having atleast one fixed side comprising a seam. Examples of such disposablearticles include training pants, pull-on diapers or adult incontinencearticles, disposable underwear for children (e.g., toddlers) or adults,and disposable panties which may be used with catamenial devices such astampons or sanitary napkins.

BACKGROUND OF THE INVENTION

Infants and other incontinent individuals wear disposable absorbentarticles to receive and contain urine and other bodily exudates.Absorbent articles having fixed sides have been popular for use in adultincontinence articles and children's toilet-training articles because itis desirable to have an absorbent article which is very garment-like inappearance and feel. (As used herein, "articles having fixed sides"refer to disposable articles such as adult incontinence briefs andtraining pants which are provided to the consumer in a pant-likeconfiguration. Thus, the articles generally have the front and rearportions joined together to form a waist hoop and leg holes. This isunlike conventional diapers which are provided to the consumer with thefront and rear portions unjoined.) For adults, the garment-likeappearance and feel can help reduce any embarrassment associated withthe use of incontinence articles. For children, especially in theirtoilet training stage, the garment-like feel and appearance can help thechild distinguish the article, such as training pants, from a diaper andcan help the child adjust to cloth undergarments.

One example of a commercially available disposable training pant isdisclosed in U.S. Pat. No. 5,246,433 entitled "Elasticized DisposableTraining Pant and Method of Making the Same", issued to Hasse et al. onSep. 21, 1993. Although this training pant has been a commercialsuccess, it still suffers because it includes seams joining the frontand rear portions which are not garment-like in appearance. Such seamsare often constructed by positioning the lateral edges of the front andrear portions of the article in a face-to-face relationship with oneanother and then gluing, sewing, heat sealing, pressure bonding orultrasonically sealing the edges to form flanges or fin seams. Theflanges or fins are unsightly if located on the outwardly facing surfaceof the article or irritating to the wearer if located on the inwardsurface. Thus, attempts have been made to reduce the outwardly orinwardly extending portions of the flanges of fin seams. However, in sodoing the process for making the seams generally becomes more complexand costly and may reduce the strength of the bond.

Thus, it would be advantageous to be able to provide a flangeless seamthat can be constructed economically. It would also be advantageous toprovide a flangeless seam that could be produces on machinery that isvery similar to that already in place. Further, it would be advantageousto reduce the amount of material that is needed to produce anaesthetically pleasing seam that is strong enough to hold together thefront and rear portions of a disposable absorbent article.

SUMMARY OF THE INVENTION

The method of then present invention provides a solution to the problemsof the prior art by providing an inexpensive means to manufactureflangeless seams. The method includes the following steps: A firstmember of the disposable article is provided. A conductive member isprovided on the first member. The first member is folded about theconductive member providing opposing first proximal and first distalportions of the first member, the conductive member being disposed atleast partially between the opposing first proximal and first distalportions. A second member of the disposable article is provided in afolded configuration juxtaposed at least a portion of the first memberto form a laminate including the first member and the second member. Anelectromagnetic field is applied across at least a portion of thelaminate to heat the conductive member to a temperature which joins atleast a portion of the first member and at least a portion of the secondmember. The resulting seam can be opened to provide the article with aflangeless seam.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the subject matter which is regarded as formingthe present invention, it is believed that the invention will be betterunderstood from the following description which is taken in conjunctionwith the accompanying drawings in which like designations are used todesignate substantially identical elements, and in which:

FIG. 1 is a perspective view of one embodiment of a disposal trainingpant in a typical in-use configuration as it would be applied to awearer comprising a seam formed by one embodiment of the presentinvention;

FIG. 2 is a plan view of the chassis of the training pant of FIG. 1having portions cut away to reveal the underlying structure, the surfacewhich will form the outer surface of the disposable article facing awayfrom the viewer;

FIG. 3 is an enlarged cross-sectional view of one embodiment of a seammade by one embodiment of the present invention in the configuration inwhich portions of the seam are joined together;

FIG. 3A is an enlarged cross-sectional view of the seam area shown inFIG. 3 in an open configuration;

FIG. 4 is an enlarged cross-sectional view of one embodiment of a seammade by one embodiment of the present invention in the configuration inwhich portions of the seam are joined together;

FIGS. 5A-G show a schematic view of a portion of one preferredembodiment of the method of the present invention;

FIG. 6 is an enlarged cross-sectional view of one embodiment of a seammade by one embodiment of the present invention in the configuration inwhich portions of the seam are joined together;

FIG. 7 is an enlarged cross-sectional view of the seam area shown inFIG. 3 in an open configuration;

FIG. 8 an enlarged cross-sectional view of one embodiment of a seam madeby one embodiment of the present invention in the configuration in whichportions of the seam are joined together; and

FIG. 9 is a cross-sectional view of one embodiment of the apparatus usedto make the seam of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the drawings, it will be noted that FIG. 1 is a perspectiveview of a unitary disposable article. A unitary disposable article isone which is intended to be discarded after it is used (i.e., it isgenerally not intended to be laundered or otherwise restored or reused).The disposable article may be provided with an absorbent assembly whichis placed in close proximity to the body of the wearer to absorb andcontain the various exudates discharged from the body. A preferredembodiment of the disposable article of the present invention,disposable training pants 20, is shown in FIG. 1.

The training pants 20 of FIG. 1, preferably comprise a chassis 14, anabsorbent assembly 22, and at least one flangeless seam 10. (As usedherein the term "flangeless seam" refers to a seam which extends fromthe disposable training pants 20 about 1/8 inch or less. Preferably theflangeless seam 10 will extend from the article about 1/16 inch or less,and more preferably 1/32 inch or less.) The chassis 14 of the presentinvention preferably has a symmetric, modified hour-glass shape. Thechassis 14 preferably comprises a front portion 56, a rear portion 58, acrotch portion 57. The chassis 14 preferably further compriseselasticized leg cuffs 32, an elasticized waistband 34, elasticized sidepanels 30 and longitudinal side regions 88. The longitudinal sideregions 88 preferably comprise a polymeric material to facilitate theseaming process which is described in greater detail below.

The training pants 20 preferably further comprises an absorbent assembly22 preferably secured to the chassis 14 by any means known in the art.The absorbent assembly preferably comprises a liquid permeable topsheet24, a liquid impervious backsheet 26 and an absorbent core 28 sandwichedbetween the topsheet 24 and the backsheet 26.

FIG. 2 is a partially cut-away perspective view of the disposablearticle 20 of FIG. 1, prior to the front portion 56 and the rear portion58 of the chassis 14 being joined together. (As used herein, the term"joined" encompasses configurations whereby an element is directlysecured to the other element by affixing the element directly to theother element, and configurations whereby the element is indirectlysecured to the other element by affixing the element to intermediatemember(s) which in turn are affixed to the other element.) As shown inFIG. 2, a preferred embodiment of the chassis 14 will comprise an outercover 48, an inner cover 46, elastic side panel members 90, elasticwaistband members 76, and elastic strands 75 secured between the innercover 46 and the outer covers 48.

The inner cover 46 is that portion of the chassis 14 which will form theinterior of the disposable training pants 20. The outer cover 48 is thatportion of the chassis 14 which will form the exterior of the disposabletraining pants 20, i.e. face away from the wearer. The outer cover 48 ispreferably liquid impervious or hydrophobic, yet breathable or perviousto vapors. The inner cover 46 and the outer cover 48 are preferablycompliant, soft feeling, and non-irritating to the wearer's skin. Asuitable inner or outer cover may be manufactured from a wide range ofmaterials, such as plastic films including microporous films; woven ornon-woven webs of natural fibers (e.g. wood or cotton fibers), syntheticfibers (e.g. polyester or polypropylene fibers), a combination ofnatural and synthetic fibers, or laminates of any of these or otherknown materials. Preferably, the inner and outer covers 46 and 48comprise a significant amount of thermoplastic fibers, typically 50% ormore, preferably 100%. Material suitable for use as an inner or outercover is Series 6700 Nonwoven manufactured by PGI Nonwovens ofLandisville, N.J.

In a preferred embodiment of the present invention, at least a portionof the inner and outer covers 46, 48 will be subjected to mechanicalstretching in order to provide a "zero strain" stretch laminate thatforms the elasticized side panels 30. Thus, the inner and outer covers46, 48 are preferably elongatable, most preferably drawable, but notnecessarily elastomeric, so that the inner and outer covers 46, 48 will,upon mechanical stretching, be at least to a degree permanentlyelongated such that they will not fully return to their originalundistorted configuration. In preferred embodiments, the inner and outercovers 46, 48 can be subjected to mechanical stretching without unduerupturing or tearing. Thus, it is preferred that the inner and outercovers 46, have a low cross-machine direction (lateral direction) yieldstrength.

Suitable "zero strain" stretch laminates and methods for producing themare disclosed in U.S. Pat. No. 5,330,458 entitled "Absorbent ArticleWith Elastic Feature Having A Portion Mechanically Prestrained" issuedto Buell et al., on Jul. 19, 1994; U.S. Pat. No. 2,075,189 issued toGalligan on Mar. 30, 1937; U.S. Pat. No. 3,025,199 issued to Harwood onMar. 13, 1962; U.S. Pat. Nos. 4,107,364 and 4,209,563 issued to Sissonon Aug. 15, 1978 and Jun. 24, 1980, respectively; U.S. Pat. No.4,834,741 issued to Sabee on May 30, 1989; and U.S. Pat. No. 5,151,092issued to Buell et al., on Sep. 29, 1992. All of the above referencedpatents are hereby incorporated by reference.

Alternatively, the inner and outer covers 46, 48 or portions thereof maycomprise a structural elastic-like film (SELF) web. A structuralelastic-like film web is an extensible material that exhibits anelastic-like behavior in the direction of elongation without the use ofadded elastic materials. SELF webs suitable for the present inventionare more completely described in the co-pending, commonly assigned U.S.Pat. No. 5,554,145, in the name of Donald C. Roe, et al., entitled"Absorbent Article with Multiple Zone Structural Elastic-Like Film WebExtensible Waist Feature" issued Sep. 10, 1996; and U.S. Pat. No.5,518,801 , in the names of Chappell, et al, entitled "Web MaterialsExhibiting Elastic-Like Behavior" issued May 21, 1996, both of which areincorporated herein by reference.

A more detailed description of a suitable training pant, as well aspreferred components and alternative embodiments, in which the methodand seams of the present invention may be used can be found in U.S. Pat.No. 5,236,430 entitled "Disposable Training Pant Having Fusion-Slit SideSeams", issued to Russell P. Bridges on Aug. 17, 1993, and U.S. Pat. No.5,246,433 entitled "Elasticized Disposable Training Pant and Method ofMaking the Same", issued to Hasse et al. on Sep. 21, 1993. Thespecification, claims and drawings of each of these patents are herebyincorporated by reference herein.

Method of Making a Flangeless Seam

One preferred method for making flangeless seams especially useful indisposable articles, such as training pants, incontinence articles andthe like is shown schematically in FIGS. 5A-5G. The step depicted inFIG. 5A shows providing a web 400 having longitudinal side edges 410that will be processed into disposable article 20 having first members200 and second members 202 to be joined. FIG. 5B shows conductive member205 provided juxtaposed at least a portion of each longitudinal sideedge 410. FIG. 5C shows the longitudinal side edges 410 being foldedover the web 400. A second conductive member 205, as shown in FIG. 5C,may be provided adjacent the folded over longitudinal side edges 410.FIG. 5D shows the chassis 14 of the disposable article 20 with the sidenotches 10 removed.

First member 200 is preferably folded about the conductive member 205providing opposing first proximal and first distal portions 210 and 212.The conductive member 205 is preferably disposed at least partiallybetween the opposing first proximal and first distal portions 210 and212. (The "proximal portion" is that portion of the first or secondmember which is joined, or will be joined, either directly orindirectly, to a portion of the disposable article 20, preferably otherthan the second member 202. The "distal portion" is that portion of thefirst member 200 or second member 202 extending from the proximalportion to the comprising the free end 214.) FIG. 5E shows the secondmember 202 of the disposable article 20 being provided juxtaposed atleast a portion of the first member 200 forming a laminate 220 of thefirst member 200, the second member 202 and the conductive member(s)205. (A more detailed drawing of the laminate 220 is shown in FIG. 3.)Other embodiments, however, are contemplated wherein the conductivemember 205 is disposed in a location other than between the firstproximal and distal portion. For example, the conductive member 205 maybe disposed between the proximal portion of the first member 200 and thedistal portion of the second member 202, between the distal portion ofthe first member 200 and the proximal portion of the second member 202or any other locations suitable for joining the first and secondmembers.

FIG. 5F shows the diaper 20 in a configuration for seaming laminate 220.An electromagnetic field is provided across the seam area 250, heatingthe conductive member(s) 205 and joining at least a portion of the firstmember 200 and the second member 202 to form seam 10. The duration ofthe electromagnetic field and/or the conductive member(s) 205 may bevaried such that opposing second proximal and second distal portions 216and 218 remain unjoined to each other. Alternatively, as shown in FIGS.6-8, a barrier member 300 may be used to prevent the joining of theopposing second proximal and second distal portions 216 and 218. Thus,the seam 10 may be opened from the configuration in which it is sealed(one embodiment is shown in FIG. 3) to a flangeless configurationwherein opposing second proximal and second distal portions 216 and 218of the second member 202 are in a relatively planar configuration withregard to one another. (An example of the seam in a planar configurationis shown in FIG. 5G and in more detail in FIG. 3A).

It should be noted that the scope of the present invention is notintended to be limited by the particular order in which the steps of themethod are described. For example, although the side notches 10 areshown to be removed first in FIG. 5D, it is contemplated that the sidenotches 10 may be removed before, after or during any other step of theprocess. Further, the method of the present invention can be performedon-line in conjunction with, or at separate time and/or in a locationremote from, the manufacture of the absorbent article which comprise theseams formed by the present method. If the process is performed on-linein conjunction with the manufacture of the absorbent article, the seamsmay be formed before, after or at the same time that the first andsecond members 200 and 202 are joined with the chassis 14 of thedisposable article 20. Also, it should be understood that the exact sizeand shape of any member comprised in the disposable article 20, as wellas the materials comprised in the members may vary depending on thedesired characteristics of the disposable article 20.

As described above, the method for manufacturing a flangeless seampreferably includes providing a first member 200 and a second member202. The chassis 14 preferably comprises at least one longitudinal sideregion 88 having a first member 200 and a second member 202. As shown inFIG. 2, the chassis 14 more preferably comprises a pair of opposinglongitudinal side regions 88, each of which comprise a first member 200and a second member 202. (Although the first members 200 are shown inFIG. 2 to be disposed in the front portion 56 and the second members 202are shown to be disposed in the rear portion 58, embodiments arecontemplated wherein the first members 200 are disposed in the rearportion 58 and the second members 202 are disposed in the front portion56.)

The first and second members 200 and 202 may be separate members joinedto the longitudinal side regions 88 or may be integral with thelongitudinal side regions 88. (As used herein, the term "integral"refers to elements that are joined to one another in such a way that theelements are neither divided nor discontinuous with the other elements.)If the first and second members 200 and 202 are joined with the chassis14, any suitable means for joining known in the art may be used. In apreferred embodiment, the first and second members 200 and 202 areextensions of the topsheet 24, the backsheet 26, both the topsheet 24and the backsheet 26 or any other element or elements of the disposablearticle that may be suitable for joining to form a seam 10.

The first member 200 and the second member 202 may comprise any materialknown in the art that is suitable for use in disposable articles such astraining pants 20 which may be joined together to form seam 10. Examplesof suitable materials include, but are not limited to polymeric films,woven webs, nonwoven webs or combinations of these or other suitablematerials known in the art. Examples of preferred materials include thecarded nonwoven DPN290 available from Fiberweb, Clopay 1401 polyethylenefilm available from the Clopay Corporation of Cincinnati, Ohio, and FS2or Plus polyethylene films available from Tredegar Film Products, Inc.,of Terre Haute Ind.

The method of the present invention further comprises the step ofproviding one or more conductive members 205, as shown in FIGS. 5B and5C. The conductive member(s) 205 heat up when an electromagnetic fieldis provided, thereby melting and joining at least a portion of the firstmember 200 and the second member 202. (It is believed the conductivemember 205 becomes heated because of Joule heating or the decay of acurrent induced in the conductive member 205 by the external magneticfield. However, Applicants do not wish to be limited to this theory.)Alternatively, the conductive member 205 may heat up a substance addedto or coated on either the first member 200, the second member 202 orthe conductive member 205. In such cases, the added material or memberbecomes active adhesively, cohesively or the like to join the firstmember 200 and the second member 202. Examples of suitable substances tobe added to the seam area are hot melt adhesives which can be obtainedfrom Ato Findley Adhesives, Inc. of Wauwatosa, Wis. as H-2120 or H-2379.

The conductive member(s) 205 may include any conductive material ormaterials and may take on any shape, size or configuration suitable forthe particular seam to be formed. Further, the conductive member(s) 205may be separate elements joined to the first or second member(s) 200 and202 or a separate member not joined to the first or second members 200and 202, but merely provided in a position to react to theelectromagnetic field while the seam 10 is being formed. Alternatively,the conductive member(s) 205 may comprise an element or material that isunitary or integrated with at least a portion of the first member 200 orsecond member 202, such as a material coextruded with the first member200 or the second member 202, or portion of the first member 200 orsecond member 202 that has been coated or impregnated to act as aconductive member.

Examples of suitable conductive members 205 include, but are not limitedto ferro-magnetic materials, metallic foils and screens such asaluminum, copper and nickel, metallic powders such as bismuth powder andany conductive materials known in the art. (As used herein the term"conductive" refers to materials which increase in temperature when inthe presence of eddy currents generated by an alternating currentflowing through an electromagnetic coil.) The conductive members 205 mayalso be in the form of a composite material such as a solution,adhesive, lotion, film, web, etc. including the conductive material.Some exemplary conductive materials are available from the AshlandChemical Company under the trade name EMAWELD. Generally, thecomposition of the conductive members 205 will be limited only by theparticular electromagnetic frequency to be used and intensity of heatwhich is needed to properly join the first member 200 and the secondmember 202. The conductive material may also be magnetic which mayincrease the efficiency of the heating due to an hysteric loss of thematerial when it is placed in an electromagnetic field.

The means by which the conductive member 205 may be provided, as wellthe timing and location for providing the conductive member 205 win bedependent on the exact conductive member 205 chosen. However, once aparticular conductive member 205 has been chosen, the conductive member205 may be provided by any suitable means known in the art. Forinstance, if a conductive member 205 comprising bismuth powder ischosen, one preferred means for providing the barrier member 205 isspraying the bismuth powder composition onto at least a portion of thefirst member 200. If the conductive member is a metallic foil, the foilmay be cut and slipped into place in the seam region 250 at any point inthe process before the seam is made. The conductive member 205 may beremoved from the seam area 250 once the seam 10 is made or may remain aspart of the finished seam 10.

In one preferred embodiment, as shown in FIG. 3, once the conductivemember 205 is provided, the first member 200 is folded about theconductive member 205. (As stated above, the exact order of the steps ofthe process are not critical, thus, the conductive member 205 may beprovided before or after the first member 200 is folded.) The fold 215preferably separates the first member 200 into two portions, a firstproximal portion 210 and an opposing first distal portion 212.Preferably, the conductive member 205 is disposed at least partiallybetween the opposing first proximal and first distal portions 210 and212, as shown in FIG. 3. The length of the first proximal portion 210and the first distal portion 212 is not critical, and either or both maycomprise any number of layers and/or folds. In fact, it is recognizedthat one way to increase the strength of the finished seam is to providemore material in the seam area 250. In an alternative embodiment, thefirst member 200 is folded about the conductive member 205 and at leasta portion of the second member 202, as shown in FIG. 4.

The method of the present invention further comprises the step ofproviding a second member 202 having a second proximal portion 218 and asecond distal portion 216. The second member 202 is preferably providedjuxtaposed at least a portion of the first distal portion 210 of thefirst member 200 at a location wherein the opposing first proximal andfirst distal portions 210 and 212 have the conductive member 205disposed between them. This forms a laminate 220 (one embodiment ofwhich is shown in FIG. 3) including the first member 200, the secondmember 202 and the conductive member 205. (As used herein, the term"laminate" refers to any number of materials that are in a generallyoverlapping configuration so as to form at least two layers. Thematerials included in the laminate may comprise single layer materialsor laminates of similar or different materials. Further, any laminatescomprised in the laminate 220 may have layers that are joined orunjoined with each other.) As shown in FIGS. 5C-5E, a conductive member205 may also be disposed between the first distal portion 210 of thefirst member 200 and the second member 202. This ensures an acceptablebond between those portions of the diaper 20, may reduce the amount ofenergy needed to create the bond and may increase the seam's strengthand integrity.

Once the materials comprised in the laminate 220 have been properlyconfigured, the seam 10 is formed. The seam 10 comprises those portionsof the laminate 220 that are joined together (i.e. at least a portion ofthe first member 200 and at least a portion of the second member 202).To form the seam 10, an electromagnetic field is applied across at leasta portion of the laminate 220. In one preferred embodiment, theelectromagnetic field is applied across the seam area 250 as shown inFIG. 3. The electromagnetic field heats the conductive member(s) 205 toa temperature which melts and joins at least a portion of the firstmember 200 and at least a portion of the second member 202. (Asdescribed above, in alternative embodiments, the conductive member(s)205 may heat a material such as a hot melt adhesive or cohesive locatedin the seam area 250 which acts to join at least a portion of the firstmember 200 and a portion of the second member 202.) Preferably, at leastthe first distal portion 210 of the first member 200 is joined to thefirst proximal portion 212 and the second distal portion 216.Preferably, at least a portion of the second proximal portion 218remains unjoined from the second distal portion 216. Thus, a flangelessseam 10 is formed that may be "opened" to the relatively planarconfiguration shown in FIG. 3A. (As used herein, the terms "open" or"opened" refer to pulling apart or separating predetermined portions ofthe laminate 220, such as the second proximal portion 218 and the seconddistal portion 216, once the laminate has been seamed so as to form arelatively planar configuration, an example of which is shown in FIG.3A.)

The electromagnetic field used to heat the conductive member 205 may beprovided by any means known in the art. In one embodiment, as shown inFIG. 9, the electromagnetic field 510 is provided by an induction coil500. (An exemplary induction coil is the Nova Series induction heatingpower supply available from Ameritherm, Inc. of Scottsville, N.Y.Specifically, a NOVA3, 3Kw power supply (220 volts, 60 Hz, 3 phase)powering a small pancake style induction coil operating at 393 Khz hasbeen found to be suitable.) The induction coil 500 is placed in theproximity of the seaming area 250 such that the electromagnetic field510 produced by the coil radiates across the conductive members 205.While not wishing to be limited by theory, it is believed that theprimary mechanism for heating the conductive member 205 is Joule heatingresulting from the decay of a current which is induced in the conductivemember 205 by the external electromagnetic field 510. A secondaryheating mechanism is found when magnetic conductive members 205 areused. The additional heating occurs due to an hysteric loss in thematerial at temperatures below the Curie temperature of the material. Ineither case, the conductive member 205 is heated to a temperature atwhich the conductive member 205 transfers enough heat energy to thesurrounding materials to melt or activate the materials, thus, joiningthem.

The method of the present invention may also include the step ofapplying a secondary joining means across the seam area 250. Suchsecondary joining means may be used to increase the seam strength or tootherwise modify the characteristics of the seam 10. The joining meansmay comprise any means suitable for joining the materials comprised inthe first and second members 200 and 202. However, a joining means mustbe chosen that will join the desired portion or portions of the firstmember 200 with the desired portion or portions of the second member 202while not joining to those portions of the first member 200 and thesecond member 202 which have been designated to remain unjoined.Suitable joining means include, but are not limited to, adhesives,pressure bonding means, heat bonding means, heat and pressure bondingmeans, ultrasound bonding means, infrared bonding means or any otherjoining means or combination of joining means known in the art.

Examples of suitable adhesive joining means include, but are not limitedto, hot melt adhesives such as Ato Findley H-2120, or Ato Findley H-2379available from Ato Findley Adhesives Corporation of Wauwatosa, Wis. Suchadhesive may be applied with slot, spiral or control spray coatingequipment such as those available from Nordson Corporation of Norcross,Ga. Examples of methods and apparatus for treating materials withultrasonic energy are disclosed in U.S. Pat. No. 3,657,033 issued toSager on Apr. 18, 1972 entitled "Method and Apparatus for ContinuousCutting and Joining of Thermoplastic Sheet Material"; U.S. Pat. No.4,400,227 issued to Riemersma on Aug. 23, 1983; U.S. Pat. No. 4,430,148issued to Schaefer on Feb. 7, 1984; U.S. Pat. No. 4,560,427 issued toFlood on Dec. 24, 1985 entitled "Ultrasonic Seal and Cut Method andApparatus"; and U.S. Pat. No. 4,693,771 issued to Payet, et al. on Sep.15, 1987 entitled "Woven Textile Fabric Having and Ultrasonically Cutand Sealed Edge and Apparatus and Process for Producing Same"; all ofwhich references are incorporated herein by reference. U.S. Pat. No.5,236,430 entitled "Disposable Training Pant Having Fusion-Slit SideSeams", issued to Russell Bridges on Aug. 17, 1993; and U.S. Pat. No.3,457,132 issued to Tuma, et al. on Jul. 22, 1969 entitled "Apparatusfor Severing and Sealing Webs of Heat Sealable Packaging Material in aSingle Operation", disclose preferred methods and apparatus for severingand sealing webs using thermal energy and mechanical energy includingultrasound. These references are also incorporated herein by reference.

The method of the present invention may also include the step ofproviding a barrier member 300, as shown in FIGS. 6-8. The barriermember 300 is provided to ensure that when the seam 10 is formed,joining the first member 200 and the second member 202, at least aportion of the first member 200 is not joined with at least a portion ofthe second member 202. The barrier member 300 may take on any shape,size or configuration suitable for the particular seam to be formed. Thebarrier member 300 may comprise a single layer or any number of layers.(The multi-layer configurations may comprise a single barrier memberfolded upon itself any number of times or may comprise layers ofunjoined material) The barrier member 300 may comprise any knownmaterial or means that will prevent the first member 200 and the secondmember 202 from becoming fully joined when the seam is formed. Further,the barrier member 300 may be a separate element joined to the firstmember or a separate member not joined to the first member 200, butmerely provided in a position to act as a barrier while the seam isbeing formed. Alternatively, the barrier member 300 may comprise anelement or material that is unitary or integrated with at least aportion of the first member 200, such as a material coextruded with thefirst member 200, or portion of the first member that has beenchemically, mechanically or otherwise manipulated to act as a barrier tothe joining means used to form the seam 10. In one embodiment, thebarrier member 300 may comprise the conductive member 205. For example,the conductive member may provide heat to form the seam 10 but may notbecome part of the seam 10. In such cases, the conductive member may beremoved when the seam is opened to a flangeless configuration.

Examples of suitable barrier members include, but are not limited toKEVLAR, NYLON, polypropylene films, polyethylene films, scrims, wovenmaterials or laminates of any these or any other suitable materialsknown in the art. Other suitable barrier member materials may comprisesilicone, talc, clay, TEFLON, lotions or any other suitable releasemeans that will prevent predetermined portions of the barrier member 205from becoming joined when the joining means 300 is applied. Yet othersuitable barrier members comprise foams; laminates of films, foamsand/or nonwoven webs; adhesives; coated or non-coated paper productssuch as paper towels or tissue; cotton and cotton-flocked films.Generally, the composition of the barrier member 205 will be limitedonly by the particular joining means 300 which will be used and thestrength characteristics necessary to provide an acceptable seam.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A method of making a flangeless seam by joiningtwo members of a disposable article, the method comprising the stepsof:providing a first member of the disposable article; folding the firstmember of the disposable article providing opposing first proximal andfirst distal portions of the first member; providing a conductive memberadjacent at least a portion of the first member; providing a secondmember of the disposable article juxtaposed at least a portion of thefirst member to form a laminate including the first member, the secondmember and the conductive member; and applying an electromagnetic fieldacross at least a portion of the laminate to heat the conductive memberto a temperature which joins at least a portion of the first member andat least a portion of the second member.
 2. The method of claim 1wherein the conductive member is integral with at least a portion of thesecond member.
 3. The method of claim 1 wherein the first member isfolded about both the conductive member and at least a portion of thesecond member.
 4. A method of making a flangeless seam by joining twomembers of a disposable article, the method comprising the stepsof:providing a first member of the disposable article; providing aconductive member adjacent at least a portion of the first member;folding the first member of the disposable article about the conductivemember providing opposing first proximal and first distal portions ofthe first member, the conductive member being disposed at leastpartially between the opposing first proximal and first distal portions;providing a second member of the disposable article in a foldedconfiguration juxtaposed at least a portion of the first member to forma laminate including the first member and the second member; andapplying an electromagnetic field across at least a portion of thelaminate to heat the conductive member to a temperature which joins atleast a portion of the first member and at least a portion of the secondmember.
 5. The method of claim 4 further comprising the step of pullingapart the first member and the second member to form a flangeless seam.6. The method of claim 4 further comprising the step of removing theconductive member after the first member and the second member have beenjoined.
 7. The method of claim 4 wherein the step of folding the firstmember includes folding the first member before the conductive member isinterposed between the opposing first proximal and first distalportions.
 8. The method of claim 4 wherein the first member includesmore than one fold.
 9. The method of claim 4 wherein the conductivemember is integral with at least a portion of the first member.
 10. Themethod of claim 4 wherein the first member is folded about both theconductive member and at least a portion of the second member.
 11. Themethod of claim 4 wherein the conductive member includes a materialselected from the following group: metallic foil, metallic screen ormetallic powder.
 12. A method of making a flangeless seam by joining twomembers of a disposable article, the method comprising the stepsof:providing a first member of the disposable article; folding the firstmember of the disposable article providing opposing first proximal andfirst distal portions of the first member; providing a heat activatableadhesive adjacent at least a portion of the first distal portion;providing a conductive member adjacent at least a portion of the firstdistal portion; providing a second member of the disposable articlejuxtaposed at least a portion of the first member to form a laminateincluding the first member, the second member, the heat activatableadhesive and the conductive member; and applying an electromagneticfield across at least a portion of the laminate to heat the conductivemember to a temperature which activates the heat activatable adhesivesuch that the adhesive joins at least a portion of the first member andat least a portion of the second member.
 13. A method of making aflangeless seam by joining two members of a disposable article, themethod comprising the steps of:providing a first member of thedisposable article; providing a conductive member adjacent at least aportion of the first member; folding the first member of the disposablearticle about the conductive member providing opposing first proximaland first distal portions of the first member, the conductive memberbeing disposed at least partially between the opposing first proximaland first distal portions; providing a second member of the disposablearticle in a folded configuration having a second proximal portion and asecond distal portion, the second distal portion being juxtaposed atleast a portion of the first member to form a laminate including thefirst member, the second member and the conductive member; providing anelectromagnetic field across at least a portion of the laminate to heatthe conductive member to a temperature which joins at least a portion ofthe first distal portion, the second distal portion and the secondproximal portion, the conductive member also preventing the joining ofthe first proximal portion with the first distal portion; removing theconductive means; and pulling apart the first proximal portion and thefirst distal portion to form a flangeless seam.
 14. The method of claim13 further including providing a secondary joining means across at leasta portion of the laminate.
 15. The method of claim 14 wherein thesecondary joining means includes an adhesive.
 16. The method of claim 14wherein the barrier member prevents the secondary joining means fromjoining the first proximal portion with the first distal portion.
 17. Amethod of making a flangeless seam by joining two members of adisposable article, the method comprising the steps of:providing a firstmember of the disposable article; providing a conductive member adjacentat least a portion of the first member; folding the first member of thedisposable article about the conductive member providing opposing firstproximal and first distal portions of the first member, the barriermember being disposed at least partially between the opposing firstproximal and first distal portions; providing a second member of thedisposable article in a folded configuration defining opposing secondproximal and second distal portions, at least a portion of the seconddistal portion being juxtaposed at least a portion of the first memberto form a laminate including the first member, the second member and theconductive member; providing a barrier member between the secondproximal portion and the second distal portion; providing anelectromagnetic field means across at least a portion of the laminate toheat the conductive member to a temperature which joins at least aportion of the first member and the second member, the conductive memberpreventing the joining means from joining the second proximal portionwith the second distal portion; removing the barrier member; and pullingapart the second proximal portion and the second distal portion to forma flangeless seam.
 18. The method of claim 17 further includingproviding a secondary joining means across at least a portion of thelaminate.
 19. The method of claim 18 wherein the secondary joining meansincludes an adhesive.
 20. The method of claim 17 wherein the barriermember prevents the secondary joining means from joining the firstproximal portion with the first distal portion.